35D4-4-110-11.pdf

TO 35D4-4-110-11

PRELIMINARY

TECHNICAL MANUAL

OPERATION AND SERVICE INSTRUCTIONS

AIRCRAFT MOUNTED APU GENERATOR HOISTING UNIT

(COMMERCIAL MANUAL)

P/N NSN

AGE70079 1730-01-532-3916

Lockheed Martin Aeronautics Company

F33657-02-C-2000

DISTRIBUTION STATEMENT E - Distribution authorized to DoD Components only (Proprietary Information), (15 August 2009). Other requests for this document shall be referred to 406 SCMS/GUHA, Robins AFB, GA, 31098. Questions concerning technical content shall be referred to 579 CBSS/GBLC.

WARNING - This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751 et seq.) or the Export Administration Act of 1979, as amended, Title 50, U.S.C., App. 2401 et seq.

Violations of these export laws are subject to severe criminal penalties.

HANDLING AND DESTRUCTION NOTICE - Comply with distribution statement and destroy by any method that will prevent disclosure of contents or reconstruction of the document.

THIS DOCUMENT CONTAINS COMMERCIAL PROPRIETARY TECHNICAL DATA. USE, COPYING, AND/OR DISCLOSURE BY THE U.S. GOVERNMENT OF THE TECHNICAL DATA CONTAINED HEREIN IS GOVERNED BY THE TERMS OF DFARS

252.2277015 TECHNICAL DATA COMMERCIAL ITEMS (NOV 1995).

© 2009 LOCKHEED MARTIN CORPORATION. ALL RIGHTS RESERVED

Published Under Authority of the Secretary of the Air Force

15 AUGUST 2009

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F33657-02-C-200F33657-02-C-200

- Distribution authori- Distribution authori is document shall be ocument shall be tent shall be referred tent shall be referred cument contains technument contains techn t seqq

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AND DESTRUCTION AND DESTRUCTIONPcontents or recocontents

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TITLE PAGE, 1

ORIGINAL ISSUE: DEC 31/07

REVISION 2: AUG 15/09

CAGE: 55820

HAMILTON SUNDSTRAND POWER SYSTEMS

4400 RUFFIN ROAD

SAN DIEGO, CA 92123-1606

C5 GROUND SUPPORT EQUIPMENT

AIRCRAFT MOUNTED APU

GENERATOR HOISTING UNIT

MODEL NUMBER APS3400

PART NUMBER AGE70079

© 2009 Hamilton Sundstrand Corporation

NOTICE

THE DATA IN THIS DOCUMENT WERE DEVELOPED ONLY TO MAINTAIN SYSTEMS AND/OR PARTS MANUFACTURED BY OR FOR HAMILTON SUNDSTRAND OR APPROVED BY HAMILTON SUNDSTRAND. THE DATA MAY NOT BE APPLICABLE TO ANY OTHER

SYSTEMS AND/OR PARTS, REGARDLESS OF THEIR APPARENT SIMILARITY TO SYSTEMS AND/OR PARTS MANUFACTURED BY OR FOR HAMILTON SUNDSTRAND OR APPROVED BY HAMILTON SUNDSTRAND. DO NOT RELY IN ANY WAY ON DATA IN THIS

DOCUMENT TO MAINTAIN OR OTHERWISE SUPPORT SYSTEMS AND/OR PARTS THAT WERE NOT MANUFACTURED BY OR FOR HAMILTON SUNDSTRAND OR APPROVED BY HAMILTON SUNDSTRAND WITHOUT EVIDENCE THAT THE FEDERAL AVIATION

ADMINISTRATION OR OTHER REGULATORY AGENCY HAS DETERMINED THAT THE DATA IN THIS DOCUMENT REMAINS VALID FOR

SUCH USE.

ITAR STATEMENT

INFORMATION CONTAINED HEREIN MAY BE SUBJECT TO THE INTERNATIONAL TRAFFIC IN ARMS (ITAR) OF THE UNITED STATES OF AMERICA. NEITHER THIS INFORMATION, NOR ANY PORTION OF INFORMATION CONTAINED HEREIN, MAY BE EXPORTED, RELEASED, OR DISCLOSED TO ANY FOREIGN ENTITY OR FOREIGN NATIONAL INSIDE OR OUTSIDE OF THE UNITED STATES

WITHOUT FIRST OBTAINING REQUIRED U.S. GOVERNMENT APPROVAL OR A VALIDATED EXPORT LICENSE. A VIOLATION OF THE ITAR MAY BE SUBJECT TO A PENALTY, AND/OR FINE, UNDER 22 U.S.C. 2778. INCLUDE THIS NOTICE WITH ANY REPRODUCED

SECTION OF THIS DOCUMENT. DIVERSION CONTRARY TO U.S. LAW IS PROHIBITED.

NOTICE

HAMILTON SUNDSTRAND ASSIGNS TO THE U.S. AIR FORCE UNDER CONTRACT F33457-02-C-2000, GOVERNMENT PURPOSE RIGHTS IN THE TECHNICAL DATA CONTAINED HEREIN FOR THE SOLE PURPOSE OF PERFORMING REPAIRS AND MAINTENANCE

ON THE PART NO. AGE70079, HOISTING UNIT, GENERATOR – AIRCRAFT MOUNTED, IN ACCORDANCE WITH DFARS CLAUSES 252.227-7013 (a) (12) AND (b) (2) AND 227.7103-5 (b). IN THE EVENT THE INTENDED RECIPIENT IS A GOVERNMENT CONTRACTOR, THAT CONTRACTOR MUST, PRIOR TO RELEASE OR DISCLOSRE, BE SUBJECT TO THE USE AND NON-DISCLOSURE AGREEMENT

AT DFARS 227.7103-7.

THIS DOCUMENT EMBODIES PROPRIETARY INFORMATION ORIGINATED OR OWNED BY HAMILTON SUNDSTRAND CORPORATION AND IS FURNISHED SUBJECT TO THE PROVISIONS OF HAMILTON SUNDSTRAND CORP. / LOCKHEED MARTIN PROPRIETARY

INFORMATION AGREEMENT DATED JULY 2, 2002.

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APS3400 GSE GENERATOR HOISTING UNIT AGE70079

RECORD OF REVISIONS

Aug 15/09 AGE70079

RECORD OF REVISIONS

REV NO. DATE CHANGE PAGES

Rev 1 May 31/09 Title Page, 1-2, 6, 8-11, 13, 15, 17, 19-20, 27-30

Rev 2 Aug 15/09 Title Page, 1-2, 7, 9-11, 13-14, 30

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APS3400 GSE GENERATOR HOISTING UNIT AGE70079

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GENERATOR HOISTING UNIT

1. TABLE OF CONTENTS

SUBJECT PAGE

1 – TABLE OF CONTENTS 1

2 – INTRODUCTION 1

3 – SAFETY ADVISORY 5

4 – OPERATING INSTRUCTIONS 7

5 – MAINTENANCE INSTRUCTIONS 8

6 – PREPARATION FOR USE 8

7 – CLEANING 9

8 – LUBRICATION 10

9 – INSPECTION 10

10 – REPAIR 16

11 – CALIBRATION 16

12 – DISASSEMBLY 16

13 – ASSEMBLY 18

14 – STORAGE AND SHIPMENT 21

15 – ILLUSTRATED PARTS BREAKDOWN 22

2. INTRODUCTION

A. These procedures give the operating instructions, maintenance procedures, and illustrated parts list for the APU Generator Hoisting Unit, part number AGE70079 (refer to Figure 1).

B. Requirements and procedures contained herein are intended for use with applicable provisions of AFOSHSTD 91-46, Materials Handling and Storage Equipment, and AFOSHSTD 91-501, Air Force Consolidated Occupational Safety Standard.

C. The generator hoisting unit provides a capability for removal and installation of the APS3400 APU generator, installed on the C5 aircraft. The hoisting unit is manually operated with a spur gear hand winch.

D. The generator hoisting unit includes two fixed rails (forward and aft support rail assemblies), a cross member swing arm assembly and a winch assembly with attachment cable (refer to Figure 2).

E. The generator hoisting unit has a rated load capacity of 80 lbs. (36.3 kg).

F. Follow the applicable local, state and federal environmental protection procedures when handling and disposing of hazardous materials.

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G. The using activity is required to maintain a record of the Generator Hoisting Unit initial receipt date, proof load test (static load test) certifications, use dates, inspection dates, and static load test dates.

H. The generator hoisting unit component and unit total weights are provided in Table 1.

Table 1 AGE70079 Hoisting Unit, Generator – Component and Unit Total Weight Data*

Part Number Component Name/Description

Weight in Pounds

AGE70079-1000 Forward Rail Assembly 3.5 lbs AGE70079-1001 Aft Rail Assembly 3.1 lbs AGE70079-1002 Cross Member/Swing Arm

Assembly

14.0 lbs

AGE70079-1003 Winch Assembly 27.0 lbs AGE70079-1004 Storage/Shipping

Container

103.6 lbs

AGE70079 Hoisting Unit, Generator (Overall Total)

151.2 lbs

* AGE70079 Drawing and Data Plates will be updated to match Table 1 weight data.

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Generator Hoisting Unit Figure 1

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Figure 2

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3. SAFETY ADVISORY

A. Scope.

(1) This publication describes processes that may require the use of chemicals, solvents, paints, or other materials that can affect a person's health or safety. It may also cover high energy procedures that can affect a person's health or safety.

Warnings are placed just ahead of these procedures to bring attention to the existence of a procedure or material that can be dangerous.

B. Significance of Material Safety Data Sheets (MSDS) and how to obtain MSDS.

(1) Refer to the materials list at the beginning of each section of this manual for materials used to repair and maintain the covered equipment.

(2) If you do not have a copy of the manufacturer’s MSDS for the materials covered in the materials list, contact the manufacturer and request that a MSDS be supplied before you use the material.

C. Purpose.

(1) The warnings bring your attention to the existence of a procedure that can affect a person’s health or safety.

(2) Cautions are provided in the maintenance publication or service bulletin to alert operating and maintenance personnel to conditions that could result in equipment damage.

D. Definitions applying to warnings.

(1) Flammable: A material that can catch fire easily and can be explosive. These materials are labeled according to the flash point of the material.

(2) Flash Point: The lowest temperature at which a flammable liquid gives off fumes that can burn.

(3) Ignition Source: Includes flames, sparks, or heat.

(4) Flames: Materials that are burning such as lit matches, propane torches, or pilot lights.

(5) Sparks: Materials such as lighted cigarettes, electrical motors, or static electricity.

(6) Heat: Any source of energy that will raise the temperature of a flammable material to its flash point and could include hot parts, heated tools, or direct sunlight.

(7) Corrosive: Acidic or alkaline material that will remove human tissue or create chemical reactions with other materials.

(8) Toxic: Material that is poisonous.

(9) Reactive: Materials that will make fumes, burn, or can be explosive when mixed with certain other materials.

(10) Shock (Electrical): The result of any source of electricity more than 50 volts that causes current to flow through a person and can result in dangerous burns to human tissues or death.

(11) Exposure: Contact with the material or physical process without protection. Contact may be by the eyes, breathing, touch, skin absorption, or swallowing.

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(12) Irritation: Any sense of pain, soreness, rash, or general discomfort.

E. Reporting materials or processes not covered in this manual.

(1) Please call (815) 226-6000, FAX (815) 966-8525, or write to Hamilton Sundstrand, Technical Publications, Department 768, 4747 Harrison Avenue, P.O. Box 7002, Rockford, IL 61125-7002, if you find a material in a Hamilton Sundstrand maintenance document that is known to be covered by a material data safety sheet (MSDS) but is not covered by a warning in the procedure.

F. Warnings and Cautions used in this manual.

WARNING: PERSONNEL SHALL CONSULT APPROPRIATE AFOSH/OSHA

GUIDANCE, MSDS INSTRUCTIONS, AND LOCAL PROCEDURES FOR

THE WEAR OF PERSONAL PROTECTIVE EQUIPMENT (PPE) WHILE

PERFORMING MAINTENANCE ON THIS EQUIPMENT. FAILURE TO

COMPLY COULD RESULT IN INJURY OR DEATH TO PERSONNEL.

WARNING: KEEP YOUR HANDS AWAY FROM THE DRUM, WIRE ROPE, AND

MOVING PARTS WHILE YOU ROTATE THE WINCH.

WARNING: KEEP PERSONNEL AWAY FROM THE PATH OF THE LOAD. A

BROKEN CABLE MAY SNAP BACK AND CAUSE INJURY.

WARNING: DO NOT USE THE GENERATOR HOISTING UNIT FOR ANY OTHER USE

OR TO LIFT ANY OTHER OBJECT BEYOND ITS DESIGN. FAILURE OF

THE HOISTING UNIT OR INJURY TO PERSONNEL MAY OCCUR.

WARNING: INSTALL THE CABLE ASSEMBLY SECURELY TO THE DRUM. A

POORLY INSTALLED CABLE ASSEMBLY MAY COME LOOSE AND

ALLOW A LOAD TO FALL.

WARNING: BEFORE AND DURING ANY HOISTING OPERATIONS DO A VISUAL

CHECK TO MAKE SURE THAT NO LESS THAN TWO (2) WRAPS OF

CABLE REMAIN ON EACH WINCH DRUM AT ALL TIMES. CHECK TO

MAKE SURE THAT THIS REQUIREMENT IS MAINTAINED WHEN THE

HOISTING CABLE IS IN ITS EXTREME LOWEST POSITION.

OTHERWISE FAILURE OF THE HOISTING UNIT OR INJURY TO

PERSONNEL MAY OCCUR.

WARNING: THE COMPLETE AGE70079 GENERATOR HOISTING UNIT,

CONTAINER AND WINCH ASSEMBLY ARE HEAVY COMPONENTS. TO

PREVENT INJURY TO PERSONNEL AND DAMAGE TO EQUIPMENT,

USE TWO (2) PEOPLE TO LIFT, HANDLE AND TRANSPORT THE UNIT.

CAUTION: THE CABLE ASSEMBLIES ARE MANUFACTURED WITH A SPECIAL

MACHINE FOR THE CORRECT ATTACHMENT AND LENGTH. MAKE

SURE YOU REPLACE THEM WITH THE CORRECT REPLACEMENT

CABLE ASSEMBLY.

CAUTION: MAKE SURE THAT THE CABLE WINDS ON THE DRUM CORRECTLY.

KEEP TENSION ON THE CABLES AT ALL TIMES TO MAKE SURE IT

WINDS CORRECTLY. IT MUST WIND EVENLY WITH NO BINDING OR

KINKING ON THE DRUM. NO TWO STRANDS SHOULD OVERLAP ON A

SINGLE PASS OVER THE DRUM.

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4. OPERATING INSTRUCTIONS

A. The following steps shall be observed when operating the generator hoisting unit:

WARNING: PERSONNEL SHALL CONSULT APPROPRIATE AFOSH/OSHA

GUIDANCE, MSDS INSTRUCTIONS, AND LOCAL PROCEDURES FOR

THE WEAR OF PERSONAL PROTECTIVE EQUIPMENT (PPE) WHILE

PERFORMING MAINTENANCE ON THIS EQUIPMENT. FAILURE TO

COMPLY COULD RESULT IN INJURY OR DEATH TO PERSONNEL.

WARNING: KEEP YOUR HANDS AWAY FROM THE DRUM, WIRE ROPE, AND

MOVING PARTS WHILE YOU ROTATE THE WINCH.

WARNING: KEEP PERSONNEL AWAY FROM THE PATH OF THE LOAD. A

BROKEN CABLE MAY SNAP BACK AND CAUSE INJURY.

WARNING: DO NOT USE THE GENERATOR HOISTING UNIT FOR ANY OTHER USE

OR TO LIFT ANY OTHER OBJECT BEYOND ITS DESIGN. FAILURE OF

THE HOISTING UNIT OR INJURY TO PERSONNEL MAY OCCUR.

WARNING: BEFORE AND DURING ANY HOISTING OPERATIONS DO A VISUAL

CHECK TO MAKE SURE THAT NO LESS THAN TWO (2) WRAPS OF

CABLE REMAIN ON EACH WINCH DRUM AT ALL TIMES. CHECK TO

MAKE SURE THAT THIS REQUIREMENT IS MAINTAINED WHEN THE

HOISTING CABLE IS IN ITS EXTREME LOWEST POSITION.

OTHERWISE FAILURE OF THE HOISTING UNIT OR INJURY TO

PERSONNEL MAY OCCUR.

(1) Refer to AFOSHSTD 91-46 and AFOSHSTD 91-501 for information about PPE.

(2) Visually inspect all components for damage with special attention to fasteners and any corrosion findings. Replace any damaged parts.

(3) Visually inspect all components for security with special attention to the cable end fasteners. Tighten any loose parts or connections and replace any cables with other than totally secure cable end fasteners.

(4) Observe the generator hoisting unit and cable. Make sure that they are properly installed and aligned for hoisting operations.

(5) Observe the winch shaft and make sure that the cable is winding smoothly and evenly.

(6) Observe the hoisting unit for signs of cable bind or slippage.

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(7) Make sure the generator is supported by hand at all times to prevent swaying or other accidental movement.

(8) Do not leave a suspended load unattended.

(9) Do not use a damaged or malfunctioning hoisting unit or equipment failure may occur.

(10) Do not modify the hoisting unit in any way or equipment failure may occur.

5. MAINTENANCE INSTRUCTIONS

A. This section contains information about equipment, consumable materials and expendable parts necessary to perform maintenance.

(1) Equipment:

Part No./Spec. No. Name

N/A Oil waste container (locally approved)

(2) Consumable Materials:

Part No./Spec. No. Name

Sandstrom 28A (MIL-PRF-46147D, Type I) (NSN 9150-01-566-7396)

Lubricant, Solid Film, Air Cured, Corrosion Inhibiting, Type I, Form II (34227)

Sprayon 201 (or equivalent) Gear and Wire Rope Lubricant (2X773)

Molykote BR-2 Plus

(NSN 9150-01-016-8986)

Grease Ball and Roller Bearing – Molykote BR-2 Plus (71984)

SAE 30 Non-detergent Oil

NOTE: SAE 30 Non-detergent Oil and Molykote BR-2 Plus are equivalent items.

(3) Expendable Parts:

(a) User maintenance and replacement of parts is accomplished at the Organizational ("O") Level except where Source, Maintenance, and Recoverability (SMR) coding does not permit.

(b) Refer to the Illustrated Parts Breakdown for the SMR codes.

6. PREPARATION FOR USE

A. Prepare the generator hoisting unit for use as follows:

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NOTE: The item numbers in parenthesis in these procedures correspond to the illustrated parts breakdown. Refer to Figure 6 in the Illustrated Parts Breakdown.

(1) Remove the hoisting unit from the storage container as follows:

(a) Open the storage container.

(b) Open the two rubber flexible draw latches (520) and remove the forward fixed rail (10).

(c) Open the two rubber flexible draw latches (520) and remove the aft fixed rail (60).

(d) Open the rubber flexible draw latch (520) that secures the cross-member/swing arm assembly (110).

(e) Unlatch the hinged panel and remove the cross-member/swing arm assembly.

(f) Open the rubber flexible draw latch (510) and carefully remove the winch assembly module (150).

NOTE: Make sure that the cable does not catch on the storage container.

(g) Visually inspect all components as defined in Maintenance Instructions.

(h) Visually inspect all components for damage with special attention to fasteners and any corrosion findings. Replace any damaged parts.

(i) Visually inspect all components for security with special attention to the cable end fasteners. Tighten any loose parts or connections and replace any cables with other than totally secure cable end fasteners.

(j) If necessary, lubricate the components as defined in Maintenance Instructions.

(K) Install the generator hoisting unit into the aircraft. Refer to the appropriate aircraft technical order.

(l) Check to make sure that no less than two (2) wraps of cable are on the winch drum.

(m) Check to make sure that the item captive features are maintained.

(2) After Generator Hoisting Unit use, visually inspect the item for deformation, degradation and excessive wear.

7. CLEANING

A. Clean the generator hoisting unit as follows:

(1) Clean the winch every six months or when excessively dirty.

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(2) Wipe all equipment with an oily rag to remove dirt and grease.

(3) Leave a light film of oil on all surfaces to prevent rust and corrosion.

(4) Wipe off excessive amounts of oil to avoid the accumulation of dirt.

(5) Keep the hoisting unit in the storage container when not in use.

8. LUBRICATION

A. Lubricate the generator hoisting unit as follows:

(1) Lubricate the cable and cam followers with Sandstrom 28A (MIL-PRF-46147D, Type I) solid film lubricant.

NOTE: Keep the solid film lubricant spray away from the pulley and mounting bolt interface area and away from the winch bearings area.

(2) Capture the waste lubricant in an approved container and dispose of the waste in accordance with local hazardous material disposition procedures.

(3) Lubricate the bearings and shafts at all friction points every six months with 2 to 3 drops of SAE 30 non-detergent oil. Rotate the drum several times to allow the oil to penetrate, and then wipe off excess oil.

(4) Lubricate the winch gears and gear teeth before every operation and every six months with Sprayon 201 or equivalent open gear lubricant.

(5) Dispose of waste lubricant in accordance with local hazardous material disposition procedures.

9. INSPECTION

A. In addition to the procedures provided in this manual refer to AFOSHSTD 91-46 as a supplemental instruction for inspection criteria, inspection intervals, and documentation of inspection results.

B. An annual inspection of machined surfaces, pins, fasteners, structure, and hoist is required.

C. Machined surfaces (pulleys) are to be visually inspected for signs of wear and corrosion.

D. Pins and fasteners are to be visually inspected for cracks, damage and corrosion.

E. Visually inspect all components for security with special attention to the cable end fasteners.

F. Tighten any loose parts or connections and replace any cables with other than totally secure cable end fasteners.

G. Check to ensure that item captive features are maintained. Fix any problems found.

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H. Visually inspect all structure for damage, weld cracks and corrosion.

I. For any corrosion findings affecting the painted metallic surfaces and which appear to require action to fix the problem, take action to control the corrosion in accordance with the aircraft surface paint technical order instructions.

J. If the Generator Hoisting Unit remains in storage for an extended period of time (twelve plus months), visually inspect for corrosion, other extended storage related degradation and damage at a frequency consistent with local shop policy (must be inspected at least annually – once a year).

K. Do these inspections of the generator hoisting unit before every use, or load test inspection, or at a minimum of once every 12 months:

(1) Do a visual inspection of the generator hoisting unit as follows:

(a) Check all parts for visible damage.

(b) Inspect the cam followers for chipped or cracked surfaces.

(c) Make sure the cables and cam followers are properly lubricated.

(d) Inspect for loose or stripped fasteners.

(2) Do a visual inspection of the generator hoisting unit cables as follows:

(a) Make sure the cable is installed correctly and anchored securely to the drum (refer to Figure 5).

(b) Examine the cable end fasteners to make sure that the fasteners remain secure. If the fasteners are not secure, replace the cable.

WARNING: BEFORE AND DURING ANY HOISTING OPERATIONS DO A

VISUAL CHECK TO MAKE SURE THAT NO LESS THAN TWO (2)

WRAPS OF CABLE REMAIN ON THE WINCH DRUM AT ALL TIMES.

CHECK TO MAKE SURE THAT THIS REQUIREMENT IS

MAINTAINED WHEN THE HOISTING CABLE IS IN ITS EXTREME

LOWEST POSITION. OTHERWISE FAILURE OF THE HOISTING

UNIT OR INJURY TO PERSONNEL MAY OCCUR.

(c) Periodically unwind the cable from the hoisting unit. Examine the entire length of cable for bent wires, crushed areas, birdcaging, broken or cut wires, corrosion, or other damage.

(d) While the cable is unwound, inspect the drum for roughness, sharp edges, and the presence of foreign material.

(e) Replace a cable when more than three wires are broken in one strand of one lay, or more than one wire is broken in one strand of a critical fatigue area (refer to Figure 3).

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NOTE: A critical fatigue area is defined as the working length of cable where the cable runs over a pulley, sleeve, or roller, or any section of cable within 12 in. (30.5 cm) of a swaged-on fitting.

NOTE: Lay (twist) is defined as the helical form taken by the wires in the strand and by the strand in the wire rope is characterized as the lay (twist) of the strands or wire rope, respectively.

NOTE: Length of lay (pitch) is defined as the distance parallel to the axis of the strand or cable in which a wire or strand makes one (1) complete turn about the axis is designated as the length of lay (pitch) of the strand or wire rope (refer to Figure 3).

(f) Do a static load test when any cable is replaced.

Cable Inspection – Broken Wires Figure 3

(3) Do a visual inspection of the winch assembly as follows:

(a) Inspect the winch for corrosion, pitting, or excessive wear.

(b) Make sure the winch bearings are properly lubricated.

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(c) Make sure the winch handle is installed correctly and securely.

(d) Check to make sure the winch can rotate freely in both directions.

(e) Move the winch drum with your hands. Slight play in the shaft is normal.

Excessive movement in the shaft may indicate worn or loose gears, bearing, or shaft.

(f) Replace the winch assembly when defective conditions are found.

(4) Do a visual inspection of the storage container as follows:

(a) Inspect all latches and handles for security and proper operation.

(b) Make sure all wooden supports are in good condition, with no cracks, splits, or breaks.

(c) Check the piano hinge for security and proper operation.

L. Static Load Test of the generator hoisting unit.

NOTE: Do not use the aircraft to perform the static load test. Use a suitable equivalent test rig.

(1) New Generator Hoisting Units are supplied with a current static load test and static load test (proof load test) certification documentation. Record and maintain the test information in accordance with local shop policy.

(2) Annual static load testing requirements must be completed annually thereafter by the anniversary of the Generator Hoisting Unit initial receipt date with the following exceptions:

(a) If the Generator Hoisting Unit remains unused, the initial static load test continues to apply until first usage, with a new annual static load testing requirement becoming due within twelve (12) months after the first usage date.

(b) If the Generator Hoisting Unit remains unused in the twelve (12) months following the last successful static load testing, then the existing static load testing certification continues to apply until the hoisting unit is used again, at which time a new annual static load testing requirement becomes due within twelve (12) months after the usage date.

(c) If the Generator Hoisting Unit is used at any time during the twelve (12) month period after the last static load test, then the next static load test must be completed within twelve (12) months after the last static load test date.

(d) In all cases, there is no deferral of the accompanying visual inspection requirements, which must be accomplished in accordance with the “Inspection” provisions of this technical order.

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(3) In conjunction with AFOSHSTD 91-46 requirements, do a static load test annually, or when the hoisting unit is disassembled/assembled, or when a cable assembly is replaced, or otherwise required, as follows:

(a) Set the generator hoisting unit up for the test as shown in Figure 4.

(b) Do the static load test in accordance with Figure 4. After the test is completed inspect the unit for evidence of cracks, bending, or material failure. No damage is permitted. Replace defective hardware and do the test again. Certification is required.

(4) Recertify the Generator Hoisting Unit for serviceability, to include static load testing, after any modification and/or repair per this technical order.

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Static Load Test Figure 4

STATIC LOAD TEST AT 130 LBS AS

SHOWN. HOLD AT TEST LOAD FOR 2

FULL MINUTES. INSPECT AFTER

TEST. NO DEFORMATIONS AND / OR

STRESS RELATED MATERIAL

DEFECTS ALLOWED. CERTIFICATION

REQUIRED.

“RATED LOAD”

DATA PLATE

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10. REPAIR

A. Repair of the generator hoisting unit is accomplished by replacement of defective parts.

11. CALIBRATION

A. None required.

12. DISASSEMBLY

A. Disassemble the generator hoisting unit as follows:

NOTE: Disassemble the hoisting unit only to the extent necessary to perform maintenance.

NOTE: If any cable assembly is replaced you must do the static load test. Refer to the Inspection section of this manual for the static load test instructions.

NOTE: Item numbers in this procedure correspond to the item numbers in the Illustrated Parts Breakdown.

NOTE: Keep all of the captive features and parts of the generator hoisting unit for any parts that will be replaced. It is permitted to remove captive features if it is necessary to completely remove the item. Make sure that captive features are maintained after item replacement.

(1) Disassemble the forward rail assembly (10) as follows:

(a) Remove the ball lock pin (20) from the rail support bracket (50).

(b) Remove the two retaining rings (30), flat washers (40), clevis pin (30), and clevis (45) from the rail support bracket (50).

(2) Disassemble the aft rail assembly (60) as follows:

(a) Remove the ball lock pin (70) from the rail support bracket (100).

(b) Remove the two retaining rings (80), flat washers (90), clevis pin (80), and clevis (95) from the rail bracket (100).

(3) Disassemble the cross-member/swing arm assembly (110) as follows:

(a) Remove the three ball lock pins (120) from the cross-member/swing arm assembly (110).

(b) Remove the two retaining rings (130) and round bar (135) from the cross-member/swing arm assembly (110).

(c) Remove the handle (140) from the cross-member/swing arm assembly (110).

(4) Disassemble the winch assembly (150) as follows:

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May 31/09 AGE70079

CAUTION: THE CABLE ASSEMBLIES ARE MANUFACTURED WITH A SPECIAL

MACHINE FOR THE CORRECT ATTACHMENT AND LENGTH. MAKE

SURE YOU REPLACE THEM WITH THE CORRECT REPLACEMENT

CABLE ASSEMBLY.

(a) Remove the cable assembly (160) as follows:

1 Unwind the entire length of cable of the cable assembly (160) from the hand winch (360) drum.

2 Loosen the jam nut on the hand winch (360) drum flange to disconnect the cable assembly (160) from the winch drum (refer to Figure 5).

3 Pull the end of the cable assembly (160) through the hole on the hand winch (360) drum flange.

4 From the opposite end, carefully pull the cable assembly (160) through the arm of the winch support frame (470).

5 Remove the flange nut (170) and screw (180) from the cable assembly (160).

(b) Remove the four screws (200) and two oil filled bars (190) from the winch support frame (470).

(c) Remove the three screws (220) and three oil filled bars (210) from the winch support frame (470).

(d) Remove the two bolts (230), lock washers (240), and flat washers (250) from the winch support frame (470).

(e) Remove the two clevis pins and retaining rings (260) from the winch support frame (470).

(f) Remove the two bolts (270), two lock washers (280), four flat washers (290), and two nuts (300) from the winch support frame (470).

(g) Remove the four bolts (310), four lock washers (330), eight flat washers (340), four nuts (350), and four pulleys (355) from the winch support frame (470).

(h) Remove the two bolts (320), two lock washers (330), four flat washers (340), and two nuts (350) from the winch support frame (470).

(i) Remove the two bolts (370), two lock washers (380), four flat washers (390), two nuts (400), and hand winch (360) from the winch support frame (470).

(j) Remove the bolt (410), lock washer (430), two flat washers (440), and nut

(450) from the winch support frame (470).

(k) Remove the bolt (420), lock washer (430), two flat washers (440), nut (450), and tube (460) from the winch support frame flat bar handle (465).

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(l) Remove the round bar (455) from the winch support frame (470) and winch support frame tube (475).

13. ASSEMBLY

A. Assemble the generator hoisting unit as follows:

NOTE: Item numbers in this procedure correspond to the item numbers in the Illustrated Parts Breakdown.

(1) Assemble the winch assembly (150) as follows:

(a) Install the round bar (455) in the winch support frame (470) and winch support frame tube (475).

(b) Install the tube (460) with the bolt (420), lock washer (430), two flat washers (440), and nut (450) on the winch support frame flat bar handle (465).

(c) Install the bolt (410), lock washer (430), two flat washers (440), and nut (450) on the winch support frame (470).

(d) Install the hand winch (360) with the two bolts (370), two lock washers (380), four flat washers (390), and two nuts (400) on the winch support frame (470).

(e) Install the two bolts (320), two lock washers (330), four flat washers (340), and two nuts (350) on the winch support frame (470).

(f) Install the four bolts (310), four lock washers (330), eight flat washers (340), four nuts (350), and four pulleys (355) on the winch support frame (470).

(g) Install the two bolts (270), two lock washers (280), four flat washers (290), and two nuts (300) on the winch support frame (470).

(h) Install the two clevis pins (260) on the winch support frame (470) and secure with the retaining rings (260).

(i) Install the two bolts (230), lock washers (240), and flat washers (250) on the winch support frame (470).

(j) Install the three oil filled bars (210) on the winch support frame (470) with the three screws (220).

(k) Install the two oil filled bars (190) on the winch support frame (470) with the four screws (200).

(l) Install the cable assembly (160) as follows:

1 Install the flange nut (170) and screw (180) on the cable assembly (160).

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CAUTION: THE CABLE ASSEMBLIES ARE MANUFACTURED WITH A

SPECIAL MACHINE FOR THE CORRECT ATTACHMENT AND

LENGTH. MAKE SURE YOU REPLACE THEM WITH THE

CORRECT REPLACEMENT CABLE ASSEMBLY.

CAUTION: MAKE SURE THAT THE CABLE WINDS ON THE DRUM

CORRECTLY. KEEP TENSION ON THE CABLES AT ALL TIMES

TO MAKE SURE IT WINDS CORRECTLY. IT MUST WIND

EVENLY WITH NO BINDING OR KINKING ON THE DRUM. NO

TWO STRANDS SHOULD OVERLAP ON A SINGLE PASS OVER

THE DRUM.

2 Carefully thread the cable assembly (160) through the winch support frame (470), starting from the inboard end of the carrier assembly and working towards the winch assembly (150) drum.

3 Check and make sure that the cable assembly is properly located in the groove of the sheave rollers (355).

WARNING: INSTALL THE CABLE ASSEMBLY SECURELY TO THE DRUM.

A POORLY INSTALLED CABLE ASSEMBLY MAY COME

LOOSE AND ALLOW A LOAD TO FALL.

WARNING: BEFORE AND DURING ANY HOISTING OPERATIONS DO A

VISUAL CHECK TO MAKE SURE THAT NO LESS THAN TWO

(2) WRAPS OF CABLE REMAIN ON THE WINCH DRUM AT

ALL TIMES. CHECK TO MAKE SURE THAT THIS

REQUIREMENT IS MAINTAINED WHEN THE HOISTING

CABLE IS IN ITS EXTREME LOWEST POSITION. OTHERWISE

FAILURE OF THE HOISTING UNIT OR INJURY TO

PERSONNEL MAY OCCUR.

4 Thread the cable through the hole in the hand winch (360) flange.

5 Loosen the jam nut and loop the cable around the anchor bolt (refer to Figure 5).

6 Position the anchor clip over the cable and tighten the jam nut until the cable is flattened against the drum flange.

7 Hold the cable taught and rotate the hand winch (360) handle clockwise to wind the cable onto the drum. If the cable begins to unwind when the handle is rotated clockwise, the cable is installed incorrectly. Install the cable correctly before continuing.

8 Continue to rotate the hand winch (360) handle clockwise to wind the cable onto the drum.

9 Maintain tension on the cable at all times to achieve proper cable position on the drum and to prevent accidental unwrapping.

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Cable Installation Figure 5

(2) Assemble the cross-member/swing arm assembly (110) as follows:

(a) Install the handle (140) on the cross-member/swing arm assembly (110).

(b) Install the two retaining rings (130) and the round bar (135) on the cross-member/swing arm assembly (110).

(c) Install the three ball lock pins (120) on the cross-member/swing arm assembly (110).

(3) Assemble the aft rail assembly (60) as follows:

(a) Install the clevis (95), clevis pin (80) and two flat washers (90) on the rail support bracket (100) and secure with the two retaining rings (80).

(b) Install the ball lock pin (70) on the rail support bracket (100).

(4) Assemble the forward rail assembly (10) as follows:

(a) Install the clevis (45), clevis pin (30) and two flat washers (40) on the rail support bracket (50) and secure with the two retaining rings (30).

(b) Install the ball lock pin (20) on the rail support bracket (50).

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14. STORAGE AND SHIPMENT

A. Store the generator hoisting unit as follows:

(Refer to Figure 2 and Figure 6)

(1) Open the six rubber flexible draw latches (510) and (520) in the storage container.

(2) Carefully put the winch assembly module into the area of the storage container marked “WINCH ASSEMBLY”.

(3) Make sure that the cables do not catch on the storage container.

(4) Close the rubber flexible draw latch (510) to secure the winch assembly.

(5) Install the cross-member/swing arm assembly into the area of the storage container marked “CROSSMEMBER/SWING ARM ASSEMBLY”.

(6) Close the rubber flexible draw latch (520) and latch the hinged panel (500) to secure the cross-member/swing arm assembly.

(7) Install the forward fixed rails into the area of the storage container marked “FWD

FIXED RAIL”.

(8) Close the two rubber flexible draw latches (520) to secure the fixed rail.

(9) Install the aft fixed rail into the area of the storage container marked “AFT FIXED

RAIL”

(10) Close the two rubber flexible draw latches (520) to secure the fixed rail.

(11) Close and secure the storage container as necessary.

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15. ILLUSTRATED PARTS BREAKDOWN (REFER TO FIGURE 6)

A. This section includes the illustrations and tables that describe the assemblies, subassemblies, and detailed parts for the Generator Hoisting Unit, part number

AGE70079.

B. Vendor codes used in this manual and parts breakdown are listed below.

Code Name and Address

12437 Thern Inc.

5712 Industrial Park Rd Winona, MN 55987-1448

2X773 Jayco Products Co. Inc.

1221 Cushman Ave San Diego, CA 92110-3900

3A054 McMaster Carr Supply Co.

9630 Norwalk Blvd Santa Fe Springs, CA 90670-2932

34227 Sandstrom Products Company 224 S. Main Street Port Byron, IL 61275-9501

55820 Hamilton Sundstrand Power Systems 4400 Ruffin Road PO Box 85757 San Diego, CA 92186-5757

71984 Dow Corning Corporation 2200 W. Salzberg Rd.

Midland, MI 48686-0994

94222 Southco Customer Technical Support 210 N. Briton Lake Road PO Box 0116 Concordville, PA 19331-0116 Phone: (610) 459-4000 Fax: (610) 459-4012

99862 Carr Lane Mfg Co.

4200 Carr Lane Ct St. Louis, MO 63119-2129

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Figure 6 (Sheet 1 of 7)

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Figure 6 (Sheet 2 of 7)

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Figure 6 (Sheet 3 of 7)

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Figure 6 (Sheet 4 of 7)

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Figure 6 (Sheet 5 of 7)

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Figure 6 (Sheet 6 of 7)

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Figure 6 (Sheet 7 of 7)

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FIG.

ITEM

PART

NUMBER

SMR

CODE 1 2 3 4 5 6 7 NOMENCLATURE

EFF

CODE

UNITS

PER

ASSY

-1 AGE70079 PEOOZU HOISTING UNIT, GENERATOR – AICRAFT

MOUNTED (55820)

RF

10 AGE70079-1000 PEOOZN . RAIL ASSEMBLY – FORWARD SUPPORT

(55820)

20 CL-5-BLPB-0.75-S-C PAOZZN . . PIN – BALL LOCK (99862) 1

30 93890A612 PAOZZN . . PIN – CLEVIS GROOVED, WITH

RETAINING RINGS (3A054)

40 AGE70079-43 PAOZZN . . WASHER – FLAT FINISHED

(1/4 NOM. I.D. X 0.125 THICK)

(NOTE 1)

45 AGE70079-20 PAOZZN . . CLEVIS (FLAT BAR 1.38 X 1.50) (55820) 1

50 AGE70079-100 PEOOZN . . BRACKET ASSEMBLY – SUPPORT

60 AGE70079-1001 PEOOZN . RAIL ASSEMBLY – AFT SUPPORT (55820) 1

70 CL-5-BLPB-0.75-S-C PAOZZN . . PIN – BALL LOCK (99862) 1

80 93890A612 PAOZZN . . PIN – CLEVIS GROOVED, WITH

RETAINING RINGS (3A054)

90 AGE70079-43 PAOZZN . . WASHER – FLAT FINISHED

(1/4 NOM. I.D. X 0.125 THICK)

(NOTE 1)

95 AGE70079-20 PAOZZN . . CLEVIS (FLAT BAR 1.38 X 1.50) (55820) 1

100 AGE70079-101 PEOOZN . . BRACKET ASSEMBLY – SUPPORT

110 AGE70079-1002 PEOOZN . CROSS MEMBER/SWING ARM

ASSEMBLY (55820)

120 CL-8-ABPL-2.00-S-

4BALL-C

PAOZZN . . PIN – ADJUSTABLE BALL LOCK (99862) 3

130 98410A142 PAOZZN . . RING – RETAINING (3A054) 2

135 AGE70079-19 PAOZZN . . BAR – ROUND ( 0.875) (55820) 1

140 62705K41 PAOZZN . . HANDLE – FOLD-AWAY REVOLVING

(3A054)

150 AGE70079-1003 PEOOZN . WINCH ASSEMBLY (55820) 1

160 AGE70079-103 PAOZZN . . CABLE ASSEMBLY (55820) 1

170 AGE70079-37 PAOZZN . . . NUT – FLANGE

(#10–24) (NOTE 1)

180 AGE70079-30 PAOZZN . . . SCREW – SOC. SHOULDER

(0.25 DIA. X 0.75) (NOTE 1)

190 AGE70079-24 PAOZZN . . BAR – OIL FILLED CAST NYLON

(0.75 X 1.00) (NOTE 1) (3A054)

ATTACHING PARTS

200 AGE70079-54 PAOZZN . . SCREW – SOC. BUTTON HEAD

(#10–24 X 0.25) (NOTE 1)

NOTE 1 – ITEM MAY BE PROCURED COMMERCIALLY.

- ITEM NOT ILLUSTRATED

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FIG.

ITEM

PART

NUMBER

SMR

CODE 1 2 3 4 5 6 7 NOMENCLATURE

EFF

CODE

UNITS

PER

ASSY

210 AGE70079-25 PAOZZN . . BAR – OIL FILLED CAST NYLON

(0.75 X 1.00) (NOTE 1) (3A054)

ATTACHING PARTS

220 AGE70079-54 PAOZZN . . SCREW – BUTTON HEAD

(#10–24 X 0.25) (NOTE 1)

230 AGE70079-55 PAOZZN . . BOLT – HEX HEAD

(1/4–20 X 0.50) (NOTE 1)

240 AGE70079-57 PAOZZN . . WASHER – LOCK

(1/4 NOM. I.D.) (NOTE 1)

250 AGE70079-56 PAOZZN . . WASHER – FLAT

(1/4 NOM. I.D.) (NOTE 1)

260 92735A263 PAOZZN . . PIN – CLEVIS, GROOVED WITH

RETAINING RING (3A054)

270 AGE70079-44 PAOZZN . . BOLT – HEX HEAD

(1/2–13 X 2.75) (NOTE 1)

280 AGE70079-46 PAOZZN . . WASHER – LOCK

(1/2 NOM. I.D.) (NOTE 1)

290 AGE70079-45 PAOZZN . . WASHER – FLAT

(1/2 NOM. I.D.) (NOTE 1)

300 AGE70079-47 PAOZZN . . NUT – HEX

(1/2–13) (NOTE 1)

310 AGE70079-33 PAOZZN . . BOLT – HEX HEAD

(1/4–20 X 2.00) (NOTE 1)

320 AGE70079-34 PAOZZN . . BOLT – HEX HEAD

(1/4–20 X 2.50) (NOTE 1)

330 AGE70079-57 PAOZZN . . WASHER – LOCK

(1/4 NOM. I.D.) (NOTE 1)

340 AGE70079-43 PAOZZN . . WASHER – FLAT FINISHED

(1/4 NOM. I.D. X 0.125 THICK)

(NOTE 1)

350 AGE70079-38 PAOZZN . . NUT – HEX

(1/4–20) (NOTE 1)

355 MIL-DTL-7034-1A PAOZZN . . PULLEY (SHEAVE) 4

360 M4022PB PAOZZN . . WINCH – HAND (WITH BRAKE)

(12437)

ATTACHING PARTS

370 AGE70079-50 PAOZZN . . BOLT – HEX HEAD

(3/8–16 X 1.00) (NOTE 1)

380 AGE70079-52 PAOZZN . . WASHER – LOCK

(3/8 NOM. I.D.) (NOTE 1)

390 AGE70079-51 PAOZZN . . WASHER – FLAT

(3/8 NOM. I.D.) (NOTE 1)

400 AGE70079-53 PAOZZN . . NUT - HEX

(3/8–16) (NOTE 1)

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FIG.

ITEM

PART

NUMBER

SMR

CODE 1 2 3 4 5 6 7 NOMENCLATURE

EFF

CODE

UNITS

PER

ASSY

410 AGE70079-48 PAOZZN . . BOLT – HEX HEAD

(1/2–13 X 2.50) (NOTE 1)

420 AGE70079-49 PAOZZN . . BOLT – HEX HEAD

(1/2–13 X 6.50) (NOTE 1)

430 AGE70079-46 PAOZZN . . WASHER – LOCK

(1/2 NOM. I.D.) (NOTE 1)

440 AGE70079-45 PAOZZN . . WASHER – FLAT

(1/2 NOM. I.D.) (NOTE 1)

450 AGE70079-47 PAOZZN . . NUT – HEX

(1/2–13) (NOTE 1)

455 AGE70079-16 PAOZZN . . BAR – ROUND ( 3.00) (55820) 1

460 AGE70079-18 PAOZZN . . TUBE – ROUND

(1.50 O.D. X 0.50 W) (NOTE 1)

465 AGE70079-17 PAOZZN . . BAR – FLAT (1.75 X 5.50) (55820) 1

470 AGE70079-102 PAOZZN . . FRAME – WINCH SUPPORT (55820) 1

475 AGE70079-13 PAOZZN . . . TUBE – RECTANGULAR

(2.00 X 1.50 X 0.125W) (55820)

480 AGE70079-1004 MOOZZN . CONTAINER – STORAGE/SHIPPING

500 1063A2 PAOZZN . . LATCH – RING PULL, WITH STRIKER

PLATE AND HARDWARE (3A054)

510 J-37-20-087-10 PAOZZN . . LATCH – FLEXIBLE DRAW – T-HANDLE

STYLE (94222)

520 37-20-102-10 PAOZZN . . LATCH – FLEXIBLE DRAW – T-HANDLE

STYLE (94222)